Hibbing Taconite Company 

bgutaik Cliffs MiningCompany, Manager 

September 19, 2005 

Minnesota Pollution Control Agency 

Supervisor 

Compliance Determination Unit 

Air Quality Division 

520 Lafayette Road North 

St. Paul, MN 55155-4194 

Re: Hibbing Taconite Company 

Air Permit No. 13700061-001 

Notification of Energy and Emission Reduction Project 

To Whom It May Concern: 

With this letter, Hibbing Taconite Company ("HTC") is pleased to notify the Minnesota 

Pollution Control Agency of HTC's upcoming Energy and Emission Reduction Project. 

Because of an unplanned breakdown of the updraft drying fan in Furnace Line 3, the 

maintenance that HTC originally scheduled for October 2005 (including this energy and 

emission reduction project) will now occur in late September 2005. The project will 

involve a change to the two combustion chamber upper air inlets on the Line 3 indurating 

furnace to allow for more efficient combustion of natural gas. Specifically, the project 

will include increasing the cross-sectional area of the upper inlet air transition ducts to 

match the diameter of the combustion chambers, in order to produce a more uniform 

airflow. This change is anticipated to eliminate the need for the atomizing air that is 

currently used to push the flame out into the firing hood, because of interference to the 

lower burners' flame pattern by the existing swirling action and uneven airflow in the 

combustion chambers. The heating of this atomizing air results in higher indurating fuel 

natural gas usage. 

Based on computational fluid dynamic modeling conducted by Energy Systems 

Associates ("ESA"), ESA projects up to a 10% decrease in indurating fuel natural gas 

usage, resulting from the improvement project. A copy of ESA's modeling analysis and 

predicted indurating fuel natural gas use reductions are included as Attachment A to this 

letter. Based on ESA's modeling and calculations prepared by Barr Engineering, the 

project will not result in any increase in the lb/hour emission rate and annual emissions 

from the Line 3 furnace. In fact, the project is calculated to substantially reduce NOx 

emissions by as much as —196 tons per year. A copy of Barr Engineering's emission 

calculations is included as Attachment B to this letter. 

The project does not change any production capacities and merely seeks to realize 

indurating fuel natural gas savings (and associated emission reductions) through more 

efficient operation of the furnace. As the project does not result in any emissions 

increase as calculated under Minn. R. 7007.1200, and does not otherwise constitute a 

Highway 5 North • P.O. Box 589 • Hibbing, MN 55746-0589 • 218/262-6800 • Fax 218/262-6877 
modification of process or control equipment, no permit amendment or formal 

notification to MPCA is required prior to commencement or completion of this project. 

The purpose of this letter, therefore, is merely to keep MPCA informed regarding HTC's 

ongoing efforts to reduce energy consumption and lower emissions at its facility. 

To the extent that you have any questions regarding this project, please contact me at 

(218) 262-6856. 

Sincerely, 

Andrea J. Hayden 

Senior Environmental Coordinator 

Hibbing Taconite Company 

W/attachments 

C: E. LaTendresse 

S. Rogers 

S. Romani 

D. Skolasinski 

D. Crouch 

D. Byrne 
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Attachment B 
Barr Engineering Company 

4700 West 77th Street • Minneapolis, MN 55435-4803 

Phone: 952-832-2600 - Fax: 952-832-2601 • www.barr.corn An EEC Employer 

BARR 

Minneapolis, MN • Hibbing, MN • Duluth, MN • Ann Arbor, MI • Jefferson City, MO 

To: Andrea J. Hayden 

From: Jack Kennedy 

Subject: Combustor Redesign PSD Baseline vs. Projected Actual Emissions 

Date: May 16, 2005 

Project: 23/69-595 

c: Steven G. Rogers 

Dear Andrea: 

The purpose of this letter is to quantify whether or not a change in emissions is expected to occur at 

Hibbing Taconite Company (HTC) as a result of the combustor redesign project on its indurating Furnace 

Line 3 per federal EPA rules found at 40 CFR 52.21. 

Proposed Change: 

Hibbing Taconite proposes to modify the combustor air inlets on its indurating Furnace Line 3. The 

proposed design change will allow for more efficient natural gas combustion, and is expected to reduce 

natural gas consumption by up to 10%. The sole purpose of the project is to reduce HTC's fuel use rate. 

The project does not change HTC's taconite pellet production capacity. The design change is based on 

Energy Systems Associates (ESA) computer modeling of the combustors. ESA's modeling of proposed 

change suggests that no emission increase will occur as a result of the change. 

Task Description: 

Barr Engineering Co. was asked to document the combustor redesign project's expected change in 

emissions using the baseline actual to projected actual emissions test. This test is used to determine 

whether or not Prevention of Significant Deterioration (PSD) permitting requirements apply to a particular 

project. The test method is described in the PSD regulations at 40 CFR 52.21(a)(2)(iv)(c). The test is 

performed by taking the difference between the facility's baseline actual emission rate and its projected 

future actual emissions. If the emission change for the project shows an increase, and the increase is less 

than PSD significance levels, PSD permitting requirements do not apply. Significant emission increases 

are defined at 40 CFR 52.21(6)(23). Emission increases associated with normal demand growth, and 
To: Andrea J. Hayden 

From: Jack Kennedy 

Subject: Combustor Redesign PSD Baseline vs. Projected Actual Emissions 

Date: May 16, 2005 

Project: 23169.595 

c: Steven G. Rogers 

Page 2 of 4 

which the source is currently capable of producing do not count towards the emissions increase for the 

project. Barr calculated the change in facility wide emissions using the actual to projected actual test for 

Line 3. 

The results of the actual to projected actual emissions test, and supporting documentation can be found in 

the attached Microsoft Excel workbook, "Combustor Redesign PSD Baseline Emissions.xls". 

Barr's Approach: 

The actual to projected actual test is done by taking the difference between a facility's projected actual 

emissions and its "baseline actual emission rate". 

In general, Barr used the emission calculation procedures HTC used for its 2004 emissions inventory 

report. Emissions were calculated using HTC emission factors based on 2004 stack testing of HTC 

sources. EPA AP-42 emission factors were used for sources where test data were not available. The 

emission factors represent emissions from HTC for each Dry Short Ton (DST) of pellets produced or for 

each million Btu of energy used in the induration furnaces. The emission factors are summarized in the 

"Emission Factor" tab of that attached Excel workbook. Assumptions used in the emission calculations are 

listed at the bottom of the "Emission Factor" tab of that attached Excel workbook 

Barr calculated HTC's "baseline actual emissions" rate per 52.21(b)(48). This method allows the use of 

the highest emission rate for a 24 month period found in the 10 year period preceding the start of 

construction for the project as the actual emissions rate. HTC currently anticipates making the combustor 

changes to Line 3 in June 2005. This sets the 10 year period at June 1995 through June 2005. Actual 

emissions were calculated using HTC taconite production and fuel use data for the period June 1995 -

April 2005. 

Barr calculated HTC's projected actual emissions using HTC's projections for future operations. This 

includes HTC's anticipated 2005 production rate of 8 3 million wet long tons, which converts to 9,110,080 

Dry Short Tons (DST) of pellets per year and indurator fuel use rate goals for 2005 of 334,204 Btu/DLT, 

which converts to 298,396 Btu/DST pellets produced. The production goals represent taconite production 

that HTC could achieve without the combustor redesign project. HTC is currently capable of producing 
To: Andrea J. Hayden 

From: Jack Kennedy 

Subject: Combustor Redesign PSD Baseline vs. Projected Actual Emissions 

Date: May 16, 2005 

Project: 23/69-595 

c: Steven G. Rogers 

Page 3 of 4 

taconite pellets at this rate. Projected actual emission increases associated with normal demand growth 

were calculated using the production targets and the target fuel use rate. Projected actual emissions 

associated with the combustor redesign were calculated using HTC's production target and 90% of the fuel 

use rate goal (268,556 BtunDST pellet) to account for the energy savings from the project. 

Barr assessed the change in emissions due to the combustor redesign by comparing the emission increase 

associated with normal product demand growth (projected actual emissions with the existing combustor 

minus baseline actual emissions) to the anticipated emission rate changes associated with the redesign 

project (projected actual emissions with the redesigned combustor minus baseline actual emissions). The 

results of this analysis for the Line 3 Combustor redesign are summarized in Table 1 Below 

The projected actual emissions increases calculated for the Line 3 Combustor Redesign Project are as 

follows: 

Table 1: 

Polluant Emission Increase Tiyr: 

Projected Actual Emissions Minus Baseline Actual Emissions 

Existing Combustor Redesigned Combustor Difference 

PM 8.32 8.32 0.00 

PM10 5.14 5.14 0.00 

CO -1.38 -5.57 -4.19 

Pb 0.0008 0.0008 0.0000 

NOx -53.5 -249.9 -196.4 

SO2 1.99 1.86 -0.13 

VOC -0.56 -2.62 -2.05 

Sulfuric 

Acid Mist 

0.09 0.08 -0.01 

Emission increases for the existing combustor case are due solely to changes in projected product demand; 

HTC is currently capable of producing taconite pellets at this rate. Emission decreases associated with the 

redesigned combustor are due to the 10% reduction in fuel use from the new design. Some pollutants 

show a slight decrease in emissions in the existing combustor design case due to a lower projected fuel use 

rate than historical fuel consum_ption rates. 

The Table 1 values are estimates for Line 3 only. Calculations for the change in emissions using the actual 

to projected actual test associated with the Line 3 combustor redesign on a facility wide basis are 
To: Andrea J. Hayden 

From: Jack Kennedy 

Subject: Combustor Redesign PSD Baseline vs. Projected Actual Emissions 

Date: May 16, 2005 

Project: 23/69-595 

c: Steven G. Rogers 

Page 4 of 4 

summarized in the "Line 3 Projected Emis" tab in the attached Microsoft Excel workbook (Combustor 

Redesign PSD Baseline Emissions.xls). 

Notes: 

• Based on the Energy Systems Associates report, NO„ and CO emission rates are not expected to 

increase on a lb/MMBtu basis as a result of the redesign. ESA's report shows that the redesign 

will reduce the size of high temperature combustion zones where NOx is formed_ The redesign 

will also maintain furnace conditions conducive to full oxidation of CO and VOC's. 

• For most pollutants, the highest 24-month baseline period is the period ending in November 2004. 

• The period ending June 1997 was the highest for SO2and sulfuric acid mist. This period had 

relatively high production rates and the highest fuel oil use during the baseline period. 

• The SO2 lb/MMBtu emission factor used in the 2004 emission inventory for the induration 

furnaces appears to overstate emissions by approximately 20%. The discrepancy appears to be 

based on a fuel use during the test of 262,243 Btu/DST pellets vs. the normal fuel use of 298,396 

Btu/DST pellets. 

A copy of the spreadsheet used for these calculations (Combustor Redesign PSD Baseline Emissions.xls) 

is attached. 

Please contact me if you have any questions on this report. 

Sincerely, 

ack Kennedy 

Telephone 952-832-2913 

Email: JXK@Barr.com 
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a 

N 

0 

U) 

0 

z 

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a co 

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10 CO 

N C‘i CO V 

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00 

CO 

N 

00 

0- 

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N 

N N 

N N 

— 

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u.. 

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• '

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Annual Taconite 

Production S Tons 

a 

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Lu 

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>, 

= 

o_ 

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c 0- 

• • Cu C 

I— co 

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C) 

2 

24 moperiodsstart June 1997 Start of 10 yrperiod: June 1995 Start of Construction Jun-06 

Notesare located onthe Emission Factorsworksheet. 

CC 

0 

of C 

.1:r) 

CD 

N 

Acid M ist(15) 

0 

19 

U) 0 (q .4. 

n 

0 CO U) 

0 

> 

,- 

0 

•,- 

co 

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N 

NI 

v, 

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01 

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00 

ked Actu 

ON 

00 

CC) 

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Cr). ("0 

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CO 

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U) 6 

00 

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of 

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01 

N 

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N0 

c0 

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a) 

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a 

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0 

2 

Existing Comb 

Chamber 

Redesigned 

Comb Chamber 

IIil 

CO 

Ci 

2006 

CD 

>- CI

0 

le in Emissions Projected Actual - PSD Baseline in Tons/Yr 

Acid Mist (15) 

N 

0 I,

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0.251 

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co 

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to •,-- 

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Annual Taconite 

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118,451 

V- .4- 

C6 

V. 

Month 

Existing Comb 

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C 

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2006 2006 

a 

a 

n 

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Nat Gas 

MSCF 

Includes CreditforReducedFuel Use 

Fuel Oil Gallons 

Annual Taconite 

Production S Tons 

Month 

Existing Comb 

I Chamber 

Redesigned 

Comb Chamber 

I- 0 CD 

co 0 0 CD 

>- N 0N 
NA 

O 

O 

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Na

w 

C) 

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a) 

co 

o lT; 

m

• 

W 

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= w 

0 

0 

0 

0 

0 

24 month periodsJun-97 Start of: 10 yr period Start of Construction Jun-05 

ssion Rate in Tons 

VOCI Acid Mist(15) 1 

O 

0) '. 

..-- r 

Cr) coco 

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r 

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cD 

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CO

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CC) 

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00 

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2,528,

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x93,487 

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487 

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0) 

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". . :Novem

b r e

2005 

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H2004 April IF 2004 T October 

1 2004 September 

2004 March 

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May 

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June .a) 

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CV 

C) 

0 

0 

a 

Notesare located on theEmission Factorsworksheet. 

O 

U 

0 12- o_ 

C 0 

_c 

C 0 

S 

N 

Production S Tons 

November 

-0 

E 

C) V a) 

0 

ci 

0) 

ib 

cc • CO cg N 

63. 

N 

CD 

C 

CDca CO CO 

0 • 

CO. 

co. CO 03 

"4- 

Co : 

4:1": 

CV 

C!!. 01 

CD 

N 

N. 

N 

71".. 

:AN 

:N: N 

U)' 

CC) 

9 O 

CD 

g).: 

CD 

a) 

c) 

CD 

CO 

C) 

CO 

N. 

co 

N. • 

N. 

• 

17: 

01. 

O 

• CD 

0) 

a! lY CD: 

C) 

CO 

Co 

Co 

N 

O. 

Co 

a. 

N 

co. 

CD CV 

01 

01 

• N 

N 

N ".1 

N 

0) 

N. .1771: 

:0 

co: 

0) 

CC; 

Tr" 

N 

c! 

N 

0) 

CV 

CO 

N N O 

fV 

O 

N 

0• 

N 

N 

N 

N 

0) 

CO 

CO 

CC) 

Q: ‘77. 

N 

C') 

0 Co 

4 

co 

Nom: N. 

CV 

co 

co 

N 

N 

CO 

4. 

U) 

N- U) 

14) 

N. 

CO. 

N-. 

'9" 

co 

C.0 

N. .00 • 

0) 

N 00 

(7) 

it 

0") 

N. 

CN 

N. 

0): 

CY) 

•.C) .141 

CV 9.) 

Co 

O 

CC) 

o) 

CD 

CO 

0) 

CO 

CO 

it 

it. C44. 

it 

0? 

CO: 

CO. 

OP:: 

O. a). 

O6 

0) 

CD 

to 

a. 

C) 

0 

0 

0 •0 

0. Z. 

EE 

C) 

0 

CCs 

2 

Lc) ' cS 

0_ r. 

5 

z 

01 

.o 

E 

co 00 

4.) -0 

N. O O O 

CV 

O 0 0- 0 

4') 

O 

N; N. 

I)) 

4 

0 

N 

10 

0 0 

Co 

0 

0 

N 

0 

0 

U) 

0 

0 

N 

i Acid Mist(15) 

0 

O 

0 

N 

0 

co 

0 

0. 

O PM (6,7) I PM10 (7) 

• 

Cu 

Production STons 

Annual Taconite 

CO 

O 

O 

U) O 

O 

N 

co 

ci) 

C 

O 

w 

0 

C) 

• = 

C 

• co as 

0- 05 

E 1:13 

O ❑ 

o 

O 0- 

s. 

'E 

I— as ce 

113 g 

X u) E 

w 

O 

O 

C 

0 

N 'Cr 
I PollutantsMo

nthly Emission Rate in Tons 

Acid Mist (15)1 

CO NI" o d tO Loo, CO 

,.--c--L-rt-rt-n 

U) N- N- "tt' CO N. 

 . 

10 0 

_,. 

N 

c.- 

U) CD 0) NI- o N-- .,- 

,qN 

v. 

c.- 

co 

LO -.:t' N CO N.- CD 0) tO N. L--- CO CO 0 

CO N 

CO 

N 1-- c- CO CO (C) 0) N. (2) DO 00 

CO 

N- LO ,- h N CO r--- L.0 t- 00 OD 1--- CO 1,--. 

voc 

c- 0 CO U) 

64466 

d (0 CO 0 CO 0 

, 4.241 

"cl- t- 0 O U) LO t- 0 

666646446 

c0 00 (0 CO NI- CO 00 N- CO 0 

7 4.521 N r CO CO N. 0 CO I-- 

6444444664 

Nt CO 0) N-- C3 CO CO 

T 

Nt 

CO 

5.07 

CC 0 Nt N.-- CO CO 0 LO 

444444666 

CO CO t- CO 0) 0 NI- 0 CO 0 

,......, 

O 

C.4 

O 

CO ..L33.27 1 

0) CO 

,-- CO 

CO 0) 

d CO 

0) CO 

N CO 

CD N 

(3) CO 

CO N. 

r- CO 

N- (0 

0 CO 

C) 0 

0 

CO N 

CO N 

I, 0 

N. cc) 

NI- ID 

CO CO 

0) CO 

 N 1--- , 

00 t- CO CO 

CO 

CA 01 0 

36.281 32.49 

0 cr) 

'T 

CO Ln 

CO 

CO N. 

CO 

N 1.-- 

CO 

0 co 

CO 

0) co 

CO 

N Nt 

CO 

"1- co 

CO dr-661---:66666661-664-:44,6 

0) -LCO 

-L- N. 

CO 

t- N 

NC 

Nr--. 

CO 

CO 

CO 

CO 

CO CO 

CO 

0 NICO cc) co 

CO 

1.0 CA 

CO 

N 

r.-- 

NI39.93 

0 NIai CO 

X 

0 

2 

L 478.401 

437.17 

L443.071 CO N 

U) 

co NIL 485.571 

0 '4' 0) d 

LONONNO N-00000d 

466666 CO CO N-- NI- CO d 

521.52 

466.11 

456.91 

CO 'Tr CO 

cr 

CO 

,1' 

NO..-d-Wccov-m,..com 

L4i6664 NI- 'Cr Nr `O' N- 

•(1- 454.55 

442.98 

NW C) 

Co 

,:lr 

Na) 

00 

r2r til 489.81 

(0 

xt 

NM 

coo 

(.14 CO "4- 

L 387.241 

"zt `I" 

COOt-NO0 oommt-7 

re566- LOt-Nc-t- 

"zr d NI486.82 

CO 

CO 

.1- 

ON 

.,-6 . Lo 

00 'cl' 

Pb 

0 01357

u oe 0-0 

0.013951 0.01545 

N CD CD 

O 

r 0.01295 

L1.91.0"0 

o 

n 0 0 

OW 

66 

co 

10 

r 

o 

0.01494 

N 

CO r 

o 

(OW d6 0.01561 

0.01232 

0.01261 

CO N NIr O 

0.01325] 

N (.0 

CO 

c) 

6 0.01514 0.01459 

0) 

••■-• (0 

0 rr.,- 

666 

... NI- U) 

a 

co CD NC 

c) 

0.01485 

CO N.- LO 

•,- 

d 

_ 

0.01473 

0.01362 

CO CD CO 

r 

o 

a 0.01343 

CO CO LC) 

o 

rrr 

666 

CO d d 

c) 

CO CO Cl) 

o 

0.015321 0.01437 

CD LO (0 

0 rr..- 

666 

CO 0 (0 

0 

c- CO U) 

0 

[ co 

6 co 

...-- 

CD NI- CO LO 

66666066 

Cr) NI" 

......,- 

0 LO III N- N CO 

..,--- 

1000 1 CO CO CO c1 CO 0 

..,—,-,....- 

CO CO N 0 CO CO `,"' LO 

,- 

'Cr 

co 

CO Cr") CV LC) CO LO N. N 

,..-- 

CO CO CO U) 

E--:66,-.6661:666666605666606666606666 

01 CO CO 

0) 

..,-,-,-..- 

Cr) CO 0 0 0) d' CO 01 0 CO NI- CD 0 cc) 1--- 0 -L- 01 CO LC) 

.,-..,..,- 

CA NY 0 LC) 

P

SD 

0 1- 

0- 

105.47 

100.26 

CD CD 

1--: 0 

Nr N 

6 

0) 0 

csi CV 

CD CA 

.-: 0 

LC) 

r 

6 N 

NI- LO 

6 

co 

CD 

6 CO 

cN4 

L 106.20 

CO 0) 

CO CO 

066 

c- 0) cCO CO 

0) 

113.79 

,- 

CO 

666 0 

r..-cNI- CC) 

N 

r 

c112.43 

CO C \ I 

CV t-..-,- 

N- CS) 

1- 

r 

r--- 

,- 

00 

r 

t-- 

CA CO 

0.1 

CO CO 

..-- 

c- (0 

0 

.......... 

NI' N 

•,- 

6r--:(Ni46660344.:.,-.61---:66(\ir-4 

(-0 NI0 NI- CO 

c- 

.,- CO. . 

tU') CO 

tN- CO .,- 

NI• CD 

,-- c-t-c-Nc0 N.- CA 

-1- NI' 

Cd 

0 t-- 

ctO 175.92 167.50 

O 

N- ',- 

6 

0) 

,-- 

oo 

C) N 

NOW0 

66r.1641.--: 

,- 

CO 

xLO 

0 N 

0 

N 

1- 144.29 

01 CO 

0 dr.,.:6 

e-,-,-- 

•,-- 

N198.37 

162.05 

d- ( \ .1 

CO 

•-• 

0 'rt 

03 

T 

d .tr 

I-- 

T 

CO 0 

,-. N 

W 

tCO 

T 

01 

,-- 

CO 

T 

ID I"- 

0 

C \ 1 

66N661-:4(17;N:66666 ,4; 

N- 1-• 

CO 

'T 

Ln CO 

00 

T 

co 0 

CO 

T 

co 0) 

0) 

T 

co NCO 

T 

..- 

N- 

•rN 

01 

r 

CA 

Nr 

195.63 

CO 

CO 

r 

1--- CO 

CO 

r 

66646 

-,- 

CO 

r 

1-- 

00 

r 

r-- 

0 

N 203.41 

1.- 

4 0) 

= 

Nat Gas 

MSCF 

219,222 

200,332 

CD 1`.. (1, 

0) 1- 

aaa 

CO 1.0 

so 

CA N 

"L- I'm w 

CV CV 

185,475 

CO CO a) 

.4 CV N 

O 

d CO CO 

47 CO "L-NCAN 

c- tO 

et 

Nr 

cCO N Nri tL.- 1--. a) 

Co PI 

206,652 

d N N 

et 

CV N ID 

N 

CO 

so CO 

r: ONO)N010 NO.1%-NN-C4 

et CV N 

.1: 

CD 0) CO 

a; 

.1-. CO Cr) 

.= 

217,622 

CD 01 CV 

co 0 CV 

I 202,992 

N CD IC) 

N 

°ca.* OCON 

U) CD N 

N 

0 U) NI: 

N 

I 201,264 

CO 

t- N 

.t.-. N 

03 

ct LC) 

1- t-, 

C") 

131 

r- ID 

cl N 

C`l Ch CO 

co 

c197,005 

II-, N-. 

aCPI .L-. 

N- 0) CD 

CO 1- 

•e- IN. ICJ 

N CV 

et 0) rt 

,t- CA 

ID CO 0) 

C) 

r-CNI 

Fuel Oil Gallons 

a) 

N 

N

dr 

aamp00000 

14,545 

0 

cb 

0 

Iavo e in 

ir-w a) 

a) 

sci CO 

a 0 o 

o 

a 

0_ 

e7 

aa o o o a a o 

N. 

1.-- d' 

t.- 

NWN 0 

co 

a ID 

00 t‘i 

se N 

0 0 0 0 0 

G" 

,t-. i, 

,i 

l'.. 

CD 

-tNN 

ui 

..e.. 

CO 

CD 

Monthly Taconite 

Produ

ction S Tons 

CO T- U) 

CD 

t- ow 

re- U) 

CO 

CD 725,533 

804,632 

0 CO N 

4 co 

co 

er CV d 

1.... CD 

842,428 

O 

e- et 

CD In CO 

777,455 

c- id 

tN .r.• I, 

14) NI' 0 

ri •c- CO 

I,- CD N 

6 

et CD 

a) 0) d 

U) 10 CD 

co 0 U) 

ci 

P.- N. 

co LO 

0) 

0) CO CO 

r N ct 

00 CD 03 

788,244 

U) 01 C) 

C) U) 

I"- 

N 

r- NI: 

tO NI" CO 

gr- CV CD 

(Cl 0 00 

762,170 

CI CO Nt 

CO 

C.-- C.+ 

0 CV (D 

6 N CO 

0) 0 N 

r: CO 

I`•-• 

707,091 

CO N 0) 

.= 

c CO 

NI• It) CO 

cci' 0) CO 

800,050 

751,415 

0 0 MI 

mi r 

CO 

.r.. N.- CI) 

r: ch 

I, 

748,537 

N. et N 

N CD 

CO 

N CD CO 

CD 

so 

CO 

CD 0 U) 

U) 0) 

I, 

Month 

Z 

c Ca 

, 

.0 41) 

Li... 

March 1 

May 

June 

July 

August 

September 

October 

November Dece

mber 

_, 

CC 

).. 

„c cl) 

March 

CL 

ct 

cci 

June 

n 

August j 

September 

L October 

4)) 

.C1 

a) 

> 0 Z 

December 

= 

c 

--, 

. a' 

CC 

n■ 

2 

ri 

u_ 

.0 

- a, ea' -^ 

June 

July 

August 

September 

October 

November Dece

mber 

(4 

CO 

a) 

VI CD a) 

r 

Cl CO (7) 

r 

1993 

r 

CIC1r) 

r 

MMMGPM 

mmmmm 

Vw 

MCI 

V-' T 

111993 

0) 

T 

0) 

T r^ T 

MO)M00) 

MMCIvt'IVIeTts*.et•Ct 

ma)mmcommmmmm 

... 

07 

V° 

0) 

V.. VOIM l° 

II 1994 

T T ...... 

MtVCPWWWWWIDU)WWW MMMMMCOMMOIMMMO) mmmmmmmma0mmmm 

V.. X.. V° V° ..l-. 1995 

40 M 

m 

vC 0 

. Cl)

Ul • •-• 

>, 

C 

C O 

tin C) 

om 

a-c NI) 

In 

0 
N 

0 

= 

0 

• c Q. 

o m 

om 

20 

am 

oo- ()L. 

cti 0 

MM 

co 

mce 

Yc 

0 

C 

0 2 

Pollutants Monthly Emission RateinTons 

'-- Lo ,.. 

4, 

< 

U) 

co 

..- 

00 

co 

.La) 

 . 

A 

.Lc0 to . ALCO 4 . AL-. 

1- 

(NJ 

(0 

CO 

U) 

00 

 . 

CO 

co 

. 

........ 

a) 

LO 

. 

A 

LO 

. 

r 

A 

. 

r Lo 

. 

0) 

N 

. ALLn 

1- 

r 

co 

N 

1-A. 

10 

co 

T-• 

A 

r 

r 

(0 

1- 

1- 

r 

A 

VLO •,- 

CO 

•LNoOLO 

a) 

r 

70 

r 

N 

CO 

•l- 

 . 

V-/ 

TN 

. 

•l1 

T 

 . 

CO 

T 

lo 

. 

(000N00(.0c0c0 

Lo 

...... 

(.0 

 . 

LO 'Ti- 

. 

01 

. 

9 

L.) 

> 

0) 

1- 

4 

,-^ 

0 

tri 

0) 

00 

4 

U) 

a) 

4 

1- 

CO 

4 

CO 

N. 

ei 

r 

00 

4 

O 

r 

to 

4.821 

VLO 

4 

a) 

c0 

4 

N 

LO 

CD 

tri 

LO 

V) 

4 

r 

0) 

4 

er^ 

4 

A 

0) 

4 

N0) 

c6 

Up 

0) 

4 

6) 

LO 

1.6 

CO 

N 

L.6 

N 

C9 

1.6 

0 

0 

tri 

0) 

V) 

to 

(0 

(0 

to 

1 4.45 

O 

N 

4 4.92 5.08 4.82 

M 

0) 

4 

4.96 

5.08 

4.89 

LO 

A 

C) 

Z.--.. 

CI 

0 

Cl) 

0 

0 

A 

co 

0) 

cel 

A 

m 

CD 

0) 

06 

(0 

GO 

CO 

6 

(0 

a) 

A 

oi 

(1 

III 

co 

1---. 

N 

N 

et 

r--- 

CO 

1- 

e1- 

r 

(-0 

N: 

al 

CV 

1- 

4 

(0 

a) 

N 

tri 

CO 

0 

70 

oti 

(1 

A 

CO 

r-i 

ol 

CO 

CI 

6 

N 

32.631 28.84 

CD 

0) 

66 

cc) 

1- 

CO 

N 

32,651 

CO 

'Cr 

at) 

cc) 

CO 

N4 

a) 

0 

tO 

c.si .,- 

CO 

T 

1- 

CO 

N CO 

V 

(c) 

I 36.48 

29.43 28.41 33.55 

0) CO 

CI sCO A 

64ceiciitricsid 

MolcOalcOcOM 

M 1-et 

0 0 N 

c0 

0) 

Lp 

z 

r Lo 

1- 

Ln 

co 

1- 

A L0 

et 

c0 

r 

1- 

co 

1- 

..t.coiccit-rio,56oic.iO4 .,-.1Occi 

0 7,-.. 

01 

00 00 

1- 

N 

cr, 

1- 

CO 

.,- 

1- 

LO 

EN, 

et 

N 

tn 

1- 

00 

00 

LO 

N 

tO 

1- 415.2i1 

+- 

(3) 

'et 

c0 

1- 

c0 

06c.i4oim 

OD 

1- 

et 

N 

Cs 

I,- 

cc) 

et 

T 

A 

I 534.06 

1- 

0 

Oixi 

0 LOU) 

CO 

N 

0 

1 477.531 

514.64' 531.39 424.99 

co r co co 

(0 c0 (0 et 

,- critrid ,-. 46[-...: 

0 (0 c0 (0 4 4 4 .4 

r 

c1 

N- 

'V 

0) CO c0 

0 r N 

A CO CO 

'Kr 'Kr -d" 

1 454.19 

3:1 

CO 

0 

M 

r 

MOCD00 

OdOd 

e0 

(0 

N 

r 

LO 

CO 

1- T.' 

tO 

a) 

1- 1- 

0.01334 

tO 

r 

(0 

LO 

A 

(0 

inNANOM 

...... 

0i0D ,O.C..C. 

OdOOO(5 

r 

in 

(0 

et 

A 

-4- 

0.01540-1 0.01323 

1 

c0 

r rAL--.,- 

odd 

0 

(1 

a) 

(0 

A 

r 

0.015081 4 

A 

0 ‘-‘-. 

00 

dci 

(1 

(1 

0.01568 0.014171 0.01488. 

0.01268 0.01420 

N- (2) 

o0 0 

1-N -t-ANT. 

dd 0.01158 0.01368 0.01471 0.01393 0.01376 

0.01469 0.01429 0.01315 0.01263 

co 1 

0) 

N 

6) 

tr) 

al 

.,-,-..,- 

veCO 

CV 

CI 

CO 

CO 

A 

V) 

0) 

dOO6r,:0ici6ioicridOc0 

(.0 

(.0 

,--. 

I-0 

0) 

0) 

co 

00 

.3) 

(,) 

co 

A,-.,- 

10 

CO 

CO 

0) 

'Cr" 

,- 

A,- 

0) 

et 

CO 

N 

..- 

CI 

N 

cio6Octid ,-- oo 

CO 

N 

.,-,-.,....--,- 

LO 

LO 

.tco 01 

(3) 

10.33 

MUM 

0) 0) 0) CO (7 (.0 0) 

1-e- CO r LO 0) r 

.- ..,.....,- T10.25 

10.49 10.11 

9.82 

A 

r• 

E 

a. 

c'om 

LC) 

N 

r 

„L_.(6 

C) 

(f) 

110.321 

co 

c0 

A,- 

xc0 

0) 

o 

T 

0) 

elo) 

1 

(3) 

.,- 

T 

r 

O.1 

c..4 

T 

4oiO6r-:c.606dr-:c4c6 

a0 

co 

+- 

T 

CO 

(.0 

C. 

T 

0) 

c0 

eT. 

is) 

c0 

r 

T 

0) 

0) 

(7 

T 

CO 

A 

a) 

103.70 

(-0 

N 

0) 

t,itrici5 

1- 

A 

r 

T 

N 

(0 

c0 

103.76 

r 

c0 

r 

T 

0) 

L.0 

0 

T 

c0 

a) 

r 

T 

CO Ln 

1-A 

0) 0 

T. 

6646.7;44c.ict561.--:Ori 

c0 In en 't LO CO r 

(1 co 0 N N 01 0) 

r co cr) o ,-- o o 

T NAT •, r r 113.10 110.35 102.62 

99.13 

i..-:: 

clic 

...... 

M 

0- 

.-- 

05 (0 

LOVN 

co 

r 

(D 

c0 

CC) 

CO 

7 

TCr) 

rre-e-rrrNr 

Ln 

Oi 

Nco 

TV) 

+-A.:7NC) 

Lo 

4 

0) 

..- 

. 

..- 

,- 

4 

01 

. a 

181.05 

r 

r-- 

.4 

OD 

r 195.98 

N cr) , 

.,- 

I,- 

(0 

co 

10 

rrrrr 

01 . 

(0 

0 

co 

Nr 

r . 

CO 

LO 

(.0 

in . 

c 4 0) 

144.92 

Lc) 

eA 

In 

co 

CI 

co 

c,icrit.idoc.i 

rrrrrr 

OM 

LC) 

0) 

V- (0 

M 

CO 00 

190.27 

158.74 

154.17 

177.17 188.52 179.91 178.10 188.28 183.83 171.32 165.65 

Nat Gas 

MSCF 

ID 

CI) 

.3 

A 

rrrN 

CO 

it) 

CO 

co 

pildie.SCO 

N 

CO 

CO 0

17) 

C) 

a 

CO 

r 

203,387 

a) 

N CO 

CO 

..ed 

re.1 

CO 

01 I.- 

r 

225,875 210,852 

1 CO 

C) 

a) 

oi,c 

e-NN 

U) 

CO 

01 

r 

CO 

01 

eN 

212,233 

0 

CO 

N 

01 

O4o; 

rcUr 

CO 

N. 

co 

r 

A 

N 

CO 

N217,417 

et 

.10 

CO 

N. 

CO 

CO 

CO 

e0 

N. 

%F 

et 

COrcocoarNc0 

t-, C.INNPANN 

Cr) 

ecri 

N 

et 

CO_ 

N 

C) 

el N 

CO 00 

CO IS 

e-el 

243,507 

194,750 184,044 

215,288 222,550 

211,011 215,974 217,246 222,319 214,126 208,128 

Fuel Oil 

Gallons 

c0 

0 

4, 

e- 

.r.m 

CO 

07 

'tt 

N 127,585 

0 0 0 (silt; 0 0 0 0 0 

N 

et 

r, 

4 

N 51,408 

00000000000 00000000000 

Monthly Taconite 

Production S Tons 

673,028 

0 

A 

A 

op 

M 

1.0 742,982 778,842 

CO 

01 

0 

(0 

0) 

tO 591,367 

0 

A 

CD 

NF 

01 

I,- 

0 

0 

co 

(0 

r.... CO 

A 

0 

co 

N 

C) 

r..- 

LO 

er 

CO 

ci 

TO 

r••• 748,205 801,549 

CO 

OA 

r 

N 

CO 

CO 

CO 

r 

LC) 

oi 

eCO 

692,942 612,475 

co 

CO 

et 

U) 

To 

A 

ID 

CO 

4,1 

0) 

LO 

LO 

0 

A 

CO 

oi 

C) 

CO 

a) 

1.0 

N. 

CD 

r 

CO 

et 

Cro 

..- 

COi 

so 

A 

A 

A 

0) 

4 

A 

A 

660,523 739,432 774,591 624,930 603,264 712,442 766,311 725,426 716,855 765,180 744,043 

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February 

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Month 

October 

November 

December 

= 

--) 

February 

March 

II- 

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June 

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August 

Septe

mber 

October 

November 

December 

January 

February 

= 

m 

April 

m 

July 

Aug

u

st 

September 

October 

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mber 

January 

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March 

April 

May 

June 

July 

August 

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300,791 Btu/dstpellets 

N 

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r N 4-• 

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LL 

Notesare located on the Emission Factorsworksheet. 

Months in Baseline 

Total in Baseline 

PSD PollutantsMonthlyEmission Rate inTons 

Acid Mist (is) 

CO 

CD 

r 

CO 

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r. 

Nr 

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CD 

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r 

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N 

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tcy) 

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LS 

cse 

N 

Fuel Oil 

Gallons 

0 0 0 0 0 0 0 0 

MonthlyTaconite 

ProductionS Tons 

800,026 

CO 1,- 

M 

Of 

Ci 

co 

CO 1, .:1 

r 

CO 1-. 

CO 

CO 

CO 

CO 

CO 

CO 

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N CO 

N •cf N 

CO 

CO N 

N 

CO 

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CO 

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Month 

September 

October 

November 

December 

fuenuer 

February 

March 

= 

CL 

< 

›, 

c 

CD 

= 

'-') 

>, 

= 

August 

September 

October 

November December 

1- 

Cd 

0 

>- 

'CI` 

0 0 N 

Tt 

0 0 N 

•Zr 4 0 N 

11 2004 

2005 

11 2005-1 1120061 

20051 

LO 0 

Co NNNN 10 0 0 

LO 0 0 

LO 0 0 

IF 2005 

LO 0 0 N 

11 2005 

10 0 0 

N 
AP-42 Emission Factors 

Distillate Oil (11) 

PM (7) 0.0236 lb/MM Btu 

PM10 0.0118 lb/MM Btu 

CO 0.0357 lb/MM Btu 

Pb 9.00E-06 ih/MM Btu 

NOx 0.1714 Ih/MM Btu 

SO2 0.4486 113/MM Btu 

AM 0.0163 lb/MM Btu 

VOC 0.0014 lb/MM Btu 

HV 140,000 Btulgal 

AM -1-12804 Acid Mist (as 803) 

Fuel Oil WI % S 0.4 

Acid Mist lb S03/Lb SO2 per AP-42 Fuel Oil Emission Factors (15) 0,0445 

AP-42 Emission Factors 

Natural Gas (14) 

PM 0.00745 lb/MM Btu 

PM10 0,00745 lb/MM Btu 

CO 0.082 lb/MM Btu 

Ph 4,90E-07 Ih/MM Btu 

NOx 0,26923 [WM Btu 

SO2 0.000588 113/MM Btu 

AM NA 

VOC 0.00539 IbIMM Btu 

RV 1015 Btu/SCF 

HV '05 1007 Btu/SCF 

AM = H2804 Acid Mist 

WC Emission Factors (4) 

Induration Furnace 

PM (6) 0.0884 Ibis-ton 

PM10 0.0884 Ibis-ton 

CO 0.093 113/MM Btu 

Pb 3.84E-05 Ibis-ton 

NOx 4.3 Ib/MM Btu 

SO2 0.36 IbIMM Btu 

VOC 0.045 IbJMM Btu 

AM (15) 0.0445 Lb AM/Lb 602 

SO2 (10) 0.0942 Ibis-ton 

AM = H2SO4 Acid Mist 

HTC Emission Factors (5, 8) 

Non-Induration Sources 

PM (6) 

PM10 

0.02182 

0.02182 

ibis-ton 

Ibis-ton 

HTC Emission Factors (5, 9) 

NJ. five Emission Sources 

PM 6 0.3111 Ibis-ton 

PM10 0.1500 lbls-ton 

325.0 ton r 

PM10 ,ton/ r 

HibbingTaconite Company 

Emission Factors for PSD Baseline Actual Emissions Calculations 

Check Calculations vs 2004 Emissions Inventory 

2004 Pdn & Nat Gas Use In Baseline Nat Gas Use 2004 Emis Inv 

9,102,501 2,835,305 2,835,265 

PM NA (Used PM10 factors for PM where MN Perf Test Used) 

P6110 1346.86 

CO 133.82 133.82 

Pb 0.174B 0,1748 

NOx 6,187.34 6,187.26 

SO2 IS/PST EF 502 lbiLIMEdu EF SO2 IbloST SF SO2 lb/MMEItu EF 

SO2 429.50 518.01 429.50 518.00 

AM 19.10 

VOC 64.75 64.75 

Line 3 % of Production 33.3% 

Notes & Assumptions 

1. Projected emissions are based on HTC's projected pellet production rate of 9.110 million Dry Short Tons (DST) per year of pellets 

(8,3 million Wet Long Tons (WLT)lyr), and projected indurator fuel use rates of 298,396 Btu/DST pellets produced. 

2. A10% reduction in fuel use for the redesigned combustors. Per Energy System Associates report dated March 2005 

3. A 10 yr PSD baseline starting In June 1995 and ending In June 2005. See HTC Pdn Data and Fuel Usage worksheets for HTC data. 

4. In general, emission calculations forthe induration furnace are based On HTC's emission factors. The emission factors are based on 

the 2004 performance tests at Line 2. 

5. Non-Induration source emission rates were calculated by using the 2004 emissions inventory emission rates 

times the ratio of past production rates to 2004 production. See Non Ind PM Emis Factor worksheet 

6. In cases where the PM emission factor was based on MN performance lest rules, PM was assumed to be equal to PM10. 

The PM10 emission factor is a higher emission factor because the MN performance test method for PM does not Include inorganic condensable 

particulate matter,the PM10 method does (EPA Method 202). 

7. For periods when fuel oil was used, PM and PM10 emissions from induration are the sum of PM and PM10 emissions calculated from the HTC 

emission factor and PM and PM10 from fuel combustion using AP-42 factors. It was assumed that PM emissions from natural gas combustion were 

incorporated in the HTC emission factor since the #2 Line was operating on natural gas during the performance test. 

8. Emission rates for fugitive sources related to throughput were ratloed to taconite pellet production. This includes primarily sources associated 

with material transfers such as ore truck unloading. See Fug PM Emis Factor worksheet 

9. Emission rates for fugitive sources not related to throughput were assumed to be constant on a ton per year basis. The emission factor for 

these sources was divided by 12 in the monthly calculations. This includes sources such as storage piles. Storage pile emission calculations are based 

on the area of the pile rather than throughput. So, the underlying assumption is that the area allotted for these piles has remained constant 

over the baseline period. See Fug PM Emis Factor worksheet 

10. The SO2 emission factor was converted from a lb SO, /MMBtu to a lb SO2 /dry short ton pellets produced basis. EPA's AP-42 emission factors 

for natural gas combustion suggest that only 0.2% of 802 emissions come from natural gas combustion. See SO2 EF worksheet 

11. All fuel oil combusted was assumed to be distillate oil (N° 2 FO) with a heating value of 140,000 Btu/gat and 0.4 wt% sulfur. HTC has used distillate, 

No4 and No6 fuel oils in the past. HTC was not able to supply data for fuel oil use by type. Distillate oil has lower emissions than No4 or Nob fuel oil; 

so, the emission calculations are conservatively /ow. Although the sulfur specifications for distillate oil are typically 0.5 wt% 5, a 0.4 wt % S content was 

used because most fuels have less sulfur than allowed. 

12. A fuel oil use rate of 105,187 gai/yr was used for the projected actual emissions calculations for the existing design, and 10% 

less for the redesigned combustor case, This was the average fuel oil use rate of 0.0116 gal/DST pellets over the baseline period times 

the projected production rate. 

13. A fuel use rate of 298,396 Btu/DST (of pellets was used for the projected actual emission rate. Average fuel use over the baseline 

period was 300,791BtWDST. 

14. A heating value of 1,016 Btuiscf was assumed for natural gas from 1995 - 2004 and 1,007 Btuiscf for 2005. This is consistent with HTC's calculations. 

AP-42 emission factors were converted to a ibiMMBtu basis using 1020 Btuiscf as noted In the footnote to the AP-42 emission factor table. 

15. An emission factor of 0,0445 lb of sulfuric acid mist/lb SO2 was used to estimate sulfuric acid mist emissions. Under normal combustion conditions, 

some sulfur is oxidized to form sulfuric acid mist; so it is reasonable to expect that some sulfuric acid mist emissions will come from the induration 

process. Since there were no test data or AP 42 emission factors for sulfuric acid mist emissions from induration furnaces, the ratio AP-42 emission 

factors for SO2 and sulfuric acid mist (as S03) from fuel oil combustion were used to estimate sulfuric acid emissions. The emission factor also 

includes and adjustment for the difference in molecular weight between S03 and sulfuric acid (H2SO4). 

Page 15 of 23 

5117/2005 

Worksheet: Emission Factors 
HibbingTaconite Company 

Emission Factors for PSD Baseline Actual Emissions Calculations 

S02 Emission Factor Based on S02 ltddst of Pellets, June, 2004 Line 2 Testing 

SO2 lb/hr Total 

Average Duty During Test MMBtu/hr 

Average Production During Test DLT/hr 

SO2 from Natural Gas lb/hr 

SO2 from Pellets lb/hr 

SO2 from Pellets lb/DLT 

SO2 from Pellets lb/DST 

SO2 from Pellets lb/MMBtu 

Heat Input Btu/DST Pellets 

SO2 lb/MMBtu Adj for Avg Btu/DST 

AP-42 Natural Gas SO2 Emission Factor 

Hibbing Taconite 

Furnace Testing 

Hibbing, Minnesota 

38.697 Sum from Tables 2,4,6 & 8 

107.642 Average from Tables 2,4,6 & 8 

366.250 Average from Tables 2,4,6 & 8 

0.063 Duty * AP-42 

38.634 

0.1055 Test Cale of Emission Factors 

0.0942 38.697 lb/hr 

0.3595 38.697 lb/hr 

262,413 

0.2984 Avg Btu/DST 316,159 

0.000588 lb/MM Btu 

Barr Engineering Co. 

August 4, 2004 

TABLE 2 

GASEOUS POLLUTANT TEST RESULTS SUMMARY 

Line 2 Furnace Stack SV025 

Test Date 6/23/2004 6/24/2004 6/24/2004 Average 

Time Period 1732-1842 0806-0920 0945-1052 --- 

Air Flow Rate 

SCFM 165,060 164,109 167,605 165,600 

DSCFM 149,159 149,437 151,769 150,100 

EPA Method 6C Emission Results 

SO2 Concentration, ppm 9 11 10 10 

SO2 Emission Rate, lb/hr 14 16 16 15 

SO2 Emission Rate, lb/MMBtu 0.13 0.14 0.15 0.14 

SO2 Emissions from Natural Gas 0.062 0.065 0,063 0.064 

SO2 Emissions lb/dst pellet production 0.0376 0.0424 0.0427 0.0409 

EPA Method 7E Emission Results 

NOx Concentration, ppm 139 134 136 136 

NOx Emission Rate, lb/hr 148 143 148 146 

NOx Emission Rate, lb/MMBtu 1.40 1.29 1.37 1.36 

EPA Method 10 Emission Results 

CO Concentration, ppm 5.3 6.2 6.2 5.9 

CO Emission Rate, lb/hr 3.5 4.0 4.1 3.9 

CO Emission Rate, lb/MMBtu 0.033 0.036 0.038 0.036 

EPA Method 25A Emission Results 

VOC Concentration, ppm(wet basis) as propane 1.1 

1.2 

0.7 

0.8 

1.0 

1.1 

0.9 

VOC Emission Rate, lb/hr as propane 1.1 

VOC Emission Rate, lb/MMBtu 0.012 0.0071 0.011 0.010 

Heat input to the Furnace, MMBtu/hr 106 111 108 108 

Process Rate, Fired Pellet Production, dlt/hr 367 370 368 368 

TABLE 4 

GASEOUS POLLUTANT TEST RESULTS SUMMARY 

Line 2 Furnace Stack(SV026) 

Test Date 6/23/2004 6/23/2004 6/23/2004 Average 

Time Period 1126-1233 1302-1408 1437-1547 --- 

Page 16 of 23 

5/17/2005 

Worksheet: SO2 EF 
HibbingTaconite Company 

Emission Factors for PSD Baseline Actual Emissions Calculations 

Air Flow Rate 

SCFM 168,224 169,724 168,325 168,800 

DSCFM 154,998 156,505 155,250 155,600 

EPA Method 6C Emission Results 

SO2 Concentration, ppm 7.2 7.1 6.7 7.0 

SO2 Emission Rate, lb/hr 11 11 10 11 

SO2 Emission Rate, lb/MMBtu 0.11 0.10 0.10 0.10 

SO2 Emissions from Natural Gas 0.062 0.062 0.062 0.062 

SO2 Emissions Ib/dst pellet production 0.0301 0.0298 0.0283 0.0294 

EPA Method 7E Emission Results 

NOx Concentration, ppm 123, 118 117 119 

NOx Emission Rate, lb/hr 136 133 130 133 

NOx Emission Rate, lb/MMBtu 1.29 1.25 1.24 1.26 

EPA Method 10 Emission Results 

CO Concentration, ppm 4.1 4.2 4.4 4.2 

CO Emission Rate, lb/hr 2.7 I 2.9 2.9 2.8 

CO Emission Rate, lb/MMBtu 0.026 0.027 0.028 0.027 

EPA Method 25A Emission Results 

VOC Concentration, ppm(wet basis) as propane 1,1 1.1 1.1 1.1 

VOC Emission Rate, lb/hr as propane 1.3 111.111M. 

0.012 

1.3 

0.012 

1.3 

VOC Emission Rate, lb/MMBtu 0.012 0.012 

Heat input to the Furnace MMBtu/hr 106 106 105 105 

Process Rate, Fired Pellet Production, dlt/hr 368 369 365 367 

TABLE 6 

GASEOUS POLLUTANT TEST RESULTS SUMMARY 

Line 2 Furnace Stack SV027 

Test Date 6/22/2004 6/23/2004 6/23/2004 Average 

Time Period 1625-1732 705-842 0907-1015 --- 

Air Flow Rate 

SCFM 181,203 180,063 183,589 181,600 

DSCFM 168,900 173,509 173,668 172,000 

EPA Method 6C Emission Results 

SO2 Concentration, ppm 4.2 2.4 5.0 3.9 

SO2 Emission Rate, lb/hr 7.1 4.2 8.6 6.6 

SO2 Emission Rate, lb/MMBtu 0.065 0.039 0.080 0.061 

SO2 Emissions from Natural Gas 0.065 0.063 0.063 0.064 

SO2 Emissions lb/dst pellet production 0.0193 0.0113 0.0235 0.0180 

EPA Method 7E Emission Results 

NOx Concentration, ppm 84 83 85 84 

NOx Emission Rate, lb/hr 102 ' 103 106 104 

NOx Emission Rate, lb/MMBtu 0.93 ", 0.96 0.99 0.96 

EPA Method 10 Emission Results 

CO Concentration, ppm 2.4 2.8 2.7 2.7 

CO Emission Rate, lb/hr 1.8 2.2 2.0 2.0 

CO Emission Rate, lb/MMBtu 0.016 0.020 0.019 0.018 

EPA Method 25A Emission Results 

VOC Concentration, ppm(wet basis) as propane 0.9 1.1 0.7 0.9 

VOC Emission Rate, lb/hr as propane 1.1 1.4 0.9 1.1 

VOC Emission Rate, lb/MMBtu 0.010 0.013 0.008 0.010 

Heat input to the Furnace MMBtu/hr 110 108 108 108 

Process Rate, Fired Pellet Production, dltlhr 366 363 364 364 

TABLE 8 

Page 17 of 23 

5/17/2005 

Worksheet: SO2 EF 
HibbingTaconite Company 

Emission Factors for PSD Baseline Actual Emissions Calculations 

GASEOUS POLLUTANT TEST RESULTS SUMMARY 

Line 2 Furnace Stack SV028 

Test Date 6/22/2004 6/22/2004 6/22/2004 Average 

Time Period 0825-0932 1237-1341 1410-1530 -- 

Air Flow Rate 

SCFM 183,312 184,016 182,213 183,200 

USCFM 173,833 173,927 172,157 173,300 

EPA Method 6C Emission Results 

SO2 Concentration, ppm 4.2 3.2 3.1 3.5 

SO2 Emission Rate, lb/hr 7.3 5.6 5.3 6.1 

SO2 Emission Rate, lb/MMBtu 0.068 0.052 0.048 0.056 

SO2 Emissions from Natural Gas 0.063 0.064 0.065 0.064 

SO2 Emissions lb/dst pellet production 0.0198 0.0152 0.0143 0.0164 

EPA Method 7E Emission Results 

NOx Concentration, ppm 65 63 65 64 

NOx Emission Rate, lb/hr 81 79 80 80 

NOx Emission Rate, lb/MMBtu 0.75 0.72 0.73 0.73 

EPA Method 10 Emission Results 

CO Concentration, ppm 2.0 1.7 1.6 1.8 

CO Emission Rate, lb/hr 1.5 1.3 1.2 1.3 

CO Emission Rate, lb/MMBtu 0.014 0.012 0.011 0.012 

EPA Method 25A Emission Results 

VOC Concentration, ppm(wet basis) as propane 1.0 1.4 0.7 1.0 

VOC Emission Rate, lb/hr as propane 1.3 1.8 0.9 1.3 

VOC Emission Rate, lb/MMBtu 0.012 0.016 0.008 0.012 

Heat input to the Furnace MMB u/hr 108 109 110 109 

Process Rate, Fired Pellet Production, dlt/hr 365 365 365 365 

Page 18 of 23 

5/17/2005 

Worksheet: SO2 EF 
mco ,-, 0 00 

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Emission Unit Description 

Phase l Apron Feeder Phase El Apron Feeder Phase I &II Primary Ore Conveyor Line No1 Mill Feed Conveyor Line No2Mill Feed Conveyor Line No 3 Mill Feed Conveyor Line No 4 Mill Feed Conveyor Line No5 Mill Feed Conveyor Line No6 Mill Feed Conveyor Line No7Mil Feed Conveyor Line No8MillFeed Conveyor Line No 9 Mil Feed Conveyor 

Phase I Bentonite DayBin Phase II Bentonite Day Bin Phase I Hearth Layer Bin 

,Phase II Hearth LayerBin 

Phase I Hearth Layer Feed 

;Phase II Hearth Layer Feed 

Pellet Machine Discharge Line No 1 

PelletMachine Discharge Line No 2 

FPelletMachine Discharge Line No 3 

Pellet Hearth Layer Screening Pellet TransferHouse Bentonite Storage Silo - East Bentonite Storage Silo - West Paint Booth 

Ilirriestone_Storage Silo 

Emission 

Unit No. 

,-N 00 00 

00.3 & 004 I 00100 0004 0000 

600 

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023 024 

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0.35 

0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 

k(TSP) 

0.74 0.74 0.74 0.74 0.74 

0.74 0.74 0.74 0.74 0.74 0.741 

Wind S.eed 

8.4 8.4 

8.4 8.4 8.4 8.4 8.4 8.4 8.4 8.4 8.4 8.4 

a up. up, CO LO 4. m CO N * N U) 

A- A- A- N1 Cn f..- 

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Lean Ore/Rock 

TaconiteOre 

Taconite Ore 

, TaconRe Ore 

Cobber Reject Fitter Cake Fitter Cake 

1 Pellets 1 Pellets 

Pellets 

Tailin. 

ti if) r> 

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a 

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PP?. Hibbing Taconite Company 

Cliffs Mining Company, Manager 

January 26, 2006 

Minnesota Pollution Control Agency 

Supervisor 

Compliance Determination Unit 

Air Quality Division 

520 Lafayette Road North 

St. Paul, MN 55155-4194 

Re: Hibbing Taconite Company 

Air Permit No. 13700061-001 

Notification of Energy and Emission Reduction Project 

To Whom It May Concern: 

With this letter, Hibbing Taconite Company ("HTC") is pleased to notify the Minnesota 

Pollution Control Agency of HTC's upcoming Energy and Emission Reduction Project. 

The project will involve a change to the two combustion chamber upper air inlets on the 

Line 1 indurating furnace to allow for more efficient combustion of natural gas. 

Specifically, the project will include increasing the cross-sectional area of the upper inlet 

air transition ducts, in order to produce a more uniform airflow. Basically this is the 

same change as completed on Furnace Line 3 in 2005 as indicated in the September 19, 

2005 letter submitted to the MPCA. 

For Furnace Line 3, based on computational fluid dynamic modeling conducted by 

Energy Systems Associates ("ESA") in 2005, ESA projected up to a 10% decrease in 

indurating fuel natural gas usage, as a result of the improvement project. In addition to 

ESA's modeling and based on calculations prepared by Barr Engineering (both were 

included with the September 19, 2005 letter submitted to the MPCA), the project would 

not result in an increase in the lb/hour emission rate and annual emissions. Instead, the 

project was calculated to substantially reduce NOx emissions by as much as —196 tons 

per year. 

Monitoring the Furnace Line 3 performance has confirmed that the expected 10% 

decrease in natural gas usage is being achieved. The same results are expected on 

Furnace Line 1. 

As with Furnace Line 3, this Furnace Line 1 project does not change any production 

capacities and merely seeks to realize indurating fuel natural gas savings (and associated 

emission reductions) through more efficient operation of the furnace. As the project does 

not result in any emissions increase as calculated under Minn. R. 7007.1200, and does not 

otherwise constitute a modification of process or control equipment, no permit 

amendment or formal notification to MPCA is required prior to commencement or 

completion of this project. The purpose of this letter, therefore, is merely to keep the 

Highway 5 North • P.O. Box 589 • Hibbing, MN 55746-0589 • 218/262-6800 • Fax 218/262-6877 
MPCA informed regarding HTC's ongoing efforts to reduce energy consumption and 

lower emissions at its facility. 

To the extent that you have any questions regarding this project, please contact me at 

(218) 262-6856. 

Sincerely, 

--dreg J. Hayden _.) 

(

A 

Senior Environmental Coordinator 

Hibbing Taconite Company 

C: E. LaTendresse 

S. Rogers 

S. Romani 

D. Skolasinski 

D. Crouch 

D. Byrne 
Hibbing Taconite Company 

Cliffs Mining Company, Manager 

May 15, 2006 

Minnesota Pollution Control Agency 

Supervisor 

Compliance Determination Unit 

Air Quality Division 

520 Lafayette Road North 

St. Paul, MN 55155-4194 

Re: Hibbing Taconite Company 

Air Permit No. 13700061-002 

Notification of Energy and Emission Reduction Project 

To Whom It May Concern: 

With this letter, Hibbing Taconite Company ("HTC") is pleased to notify the Minnesota 

Pollution Control Agency of HTC's upcoming Energy and Emission Reduction Project. 

The project will involve a change to the two combustion chamber upper air inlets on the 

Line 2 indurating furnace to allow for more efficient combustion of natural gas. 

Specifically, the project will include increasing the cross-sectional area of the upper inlet 

air transition ducts, in order to produce a more unifoun airflow. Basically this is the 

same change as completed on Furnace Line 3 in 2005 and Furnace Line 1 in 2006, as 

indicated in the September 19, 2005 and January 26, 2006 letters (respectively) submitted 

to the MPCA. 

For Furnace Line 3, based on computational fluid dynamic modeling conducted by 

Energy Systems Associates ("ESA") in 2005, ESA projected up to a 10% decrease in 

indurating fuel natural gas usage, as a result of the improvement project. In addition to 

ESA's modeling and based on calculations prepared by Barr Engineering (both were 

included with the September 19, 2005 letter submitted to the MPCA), the project would 

not result in an increase in the lb/hour emission rate and annual emissions. Instead, the 

project was calculated to substantially reduce NOx emissions by as much as —196 tons 

per year. 

Monitoring the Furnace Lines 1 and 3 performances has confirmed that the expected 10% 

decrease in natural gas usage is being achieved. Similar results are expected on Furnace 

Line 2. 

As with Furnace Lines 1 and 3, this Furnace Line 2 project does not change any 

production capacities and merely seeks to realize indurating fuel natural gas savings (and 

associated emission reductions) through more efficient operation of the furnace. As the 

project does not result in any emissions increase as calculated under Minn. R. 7007.1200, 

and does not otherwise constitute a modification of process or control equipment, no 

peiniit amendment or formal notification to MPCA is required prior to commencement or 

Highway 5 North P.O. Box 589 • Hibbing, MN 55746-0589 • 218/262-6800 • Fax 218/262-6877 
completion of this project. The purpose of this letter, therefore, is merely to keep the 

MPCA informed regarding HTC's ongoing efforts to reduce energy consumption and 

lower emissions at its facility. 

To the extent that you have any questions regarding this project, please contact me at 

(218) 262-6856. 

Sincerely, 

4 ,,ity 

( Ulrea J. Hayden _ 

Section Manager - Environmental 

IT 

- ibbing Taconite Company 

C: E. LaTendresse 

S. Rogers 

S. Romani 

D. Skolasinski 

D. Crouch 

D. Byrne